Our Story
Welcome to Mahan Woodwinds!
A bit about me: I’ve been playing the tinwhistle since around 1997, and have always been fascinated with making my own whistles. In 2005, I bought woodworking equipment and started learning the craft. I produced my first whistle a few months later. Unfortunately, a couple of years later, I had to move because of work and had to sell almost all of my woodworking equipment.
In 2015, 3D printing was still in its infancy, and I made an April Fool’s Day joke with my whistle friends about duplicating famous makers’ whistles using scanning technology. It was just a joke, but the idea always stuck with me. A few years later, the technology had matured quite a bit, so I dusted off all my old wooden-whistle diagrams and notes and tried to design a whistle that could be 3D printed. It was a dismal failure. I just wasn’t getting the quality that I wanted, and hiring someone to modify prototypes in CAD software, and then shipping them to a 3rd party printing company became prohibitively expensive.
In 2023, I got an inexpensive 3D printer on loan from a friend, and was shocked at how much things had improved! I caught the 3D printing bug, and was soon making all kinds of toys, gadgets and household items. One of my friends reminded me of my previous efforts in making a whistle. Initially, I brushed it off, but soon the idea caught fire in my brain again. I learned enough modeling skills in Fusion 360 to transform all of my notes and designs into an engineering file, and the very next day, I had a playable whistle in my hands! It wasn’t perfect, but it was good enough that I knew that if I just kept tweaking the shape files, I’d eventually produce a whistle that I wouldn’t be ashamed to hang my name on.
Scores of prototypes later, I had a repeatable process to make a good whistle, and began selling them in a limited fashion. And now I feel ready to hang out my shingle and offer them to the world!
Watch me build a whistle!
A few Ebony wood-grained whistle bodies being printed.
Even though I’m 3D printing whistles, there’s still a fair amount of hand finishing work that has to be done to them to finish them off. 3D printing is has improved considerably since I first dabbled with it, but it’s still not perfect. I have to clean up flash and other bits of debris left over from the printing process. I have to use a reamer to ensure that the tuning slide is a snug fit, but not too snug or too loose. And sometimes (though more rarely), I need to take tools to the blade if the print didn’t come out to my satisfaction. But the software, hardware, and my skill and knowledge continually improve over time, and these finishing steps become easier. Maybe one day the technology will be on par with injection molding, and I can do all of my work in software, press a button, and have a perfect whistle. But for now, at least some work on your Mahan Whistle will bear some of my manual craftsmanship.